Method of use of a robotic frame and power transfer device

ABSTRACT

A method for movement of products is described. The method uses a facility which contains warehouse shelves, each shelf has a front, at least one moveable frame which travels to each shelf front to access the containers stored on each shelf. The moveable frame includes a repositionable storage ledge, a lifting device, and a gripping device. Mobile Robots exchange payloads between moveable frames.

PRIORITY CLAIM

This application claims priority as a continuation to U.S. applicationSer. No. 15/446,958 filed on Mar. 1, 2017, presently pending which inturn claimed priority to a U.S. Provisional Application Ser. No.62/302,070, filed on Mar. 1, 2016, presently expired. application Ser.No. 15/446,958 also claimed priority as a continuation in part of PCTapplication PCT/US2016/039010, filed on Jun. 23, 2016, presentlyexpired, which in turn claimed priority to U.S. provisional applicationSer. No. 62/231,092, filed on Jun. 24, 2015, presently expired, and U.S.provisional application Ser. No. 62/302,070, filed on Mar. 1, 2016,presently expired. The contents of each application are herebyincorporated by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The field of the invention is a system for automation of a warehouseemploying a mobile robotic frame and a power transfer system. Thecombination comprises an improved automated storage and retrievalsystem.

2. Background of the Invention

In various embodiments, the invention provides a solution for automatinga storage location which includes non-powered shelves. The storagelocation can be any job site with an inventory, such as a fulfillmentcenter, a warehouse, or a distribution center.

In one embodiment, the invention comprises a mobile robot, which movescontainers from one or more mobile frames. The frames include liftingdevices and gripping devices to move containers to and from warehouseshelves. Each shelf includes a passive container movement system whichis actuated by a robotic arm attached to the mobile frame. The roboticarm works in cooperation with a gripping device, also located on themobile frame.

Traditionally, warehouse automation systems required large mobilerobotic components which could not be deployed even if the initialwarehouse design or infrastructure did not account for roboticcomponents.

A need exists in the art for a system that allows for adding of arelatively low-cost robotic solution to a warehouse having passiveshelving units.

SUMMARY OF INVENTION

An object of the invention is to create a system for automating awarehouse. A feature of the invention is that the lifting device fromthe moveable frames retrieves needed containers from warehouse shelvesand makes them available to a mobile robot for processing. An advantageof the system is that it allows for automated deliveries within awarehouse setting without custom-built infrastructure within thewarehouse.

A further object of the invention is to automate a warehouse withoutadding powered movement mechanisms to each shelf. A feature of theinvention is that the lifting device which is included on the moveableframe includes a shelf power transfer unit which actuates a shelfmovement mechanism. An advantage of the invention is that it allows forautomation of a warehouse without adding complexity and power systems toeach shelf. A system for automated management of a high densitywarehouse comprising: warehouse shelves having multiple containerscontaining products stored thereon, wherein each shelf comprises acontainer movement mechanism; an autonomous mobile robot; and a liftingframe having one or more floor supports, vertical members, at least onehorizontal crossbar, one or more storage ledges intermediate said floorsupports and said at least one horizontal crossbar, further said liftingframe having a gripping device suspended from said at least one crossbarwherein said frame gripping device comprises a gantry arm wherein saidgantry arm receives containers from the autonomous mobile robot to placeon one or more frame ledges, wherein said gantry arm returns containersto the autonomous mobile robot from one or more frame ledges, and alifting device attached to at least one vertical member, wherein saidlifting device comprises an articulated arm having at least containerplacement tool wherein said lifting device transfers containers from oneor more frame storage ledges to and from one or more warehouse shelves.

BRIEF DESCRIPTION OF DRAWING

The invention together with the above and other objects and advantageswill be best understood from the following detailed description of thepreferred embodiment of the invention shown in the accompanyingdrawings, wherein:

FIG. 1 depicts an overview of the system pursuant to one embodiment ofthe invention;

FIG. 2 depicts an overview of an embodiment of an end of arm toolpursuant to one embodiment of the invention;

FIG. 3 depicts an overview of a gripping device pursuant to anembodiment of the invention;

FIG. 4 depicts a detailed view of an embodiment of the transmissionpoint of an invention;

FIG. 5 depicts an overview of a product loading point pursuant to oneembodiment of the invention;

FIGS. 6A-D depict an overview of power transfer alternatives pursuantone embodiment of the invention;

FIGS. 7A-B depict alternative shelf embodiment pursuant to theinvention;

FIG. 8 depicts a schematic overview of an embodiment of the system asdeployed in a facility;

FIG. 9 depicts an overview of the primary elements of one embodiment ofthe system;

FIG. 10 depicts an overview of a component of one embodiment of thesystem;

FIG. 11 depicts a detailed view of joining of components in oneembodiment of the system;

FIG. 12 depicts another view of joining of components in one embodimentof the system;

FIG. 13 depicts an overview of another component of one embodiment ofthe system; and

FIG. 14 depicts an overview of another component of one embodiment ofthe system.

DETAILED DESCRIPTION OF THE INVENTION

The foregoing summary, as well as the following detailed description ofcertain embodiments of the present invention, will be better understoodwhen read in conjunction with the appended drawings.

To the extent that the figures illustrate diagrams of the functionalblocks of various embodiments, the functional blocks are not necessarilyindicative of the division between hardware circuitry. Thus, forexample, one or more of the functional blocks (e.g. processors ormemories) may be implemented in a single piece of hardware (e.g. ageneral purpose signal processor or a block of random access memory,hard disk or the like). Similarly, the programs may be stand-aloneprograms, may be incorporated as subroutines in an operating system, maybe functions in an installed software package, and the like. It shouldbe understood that the various embodiments are not limited to thearrangements and instrumentality shown in the drawings.

As used herein, an element or step recited in the singular and proceededwith the word “a” or “an” should be understood as not excluding pluralsaid elements or steps, unless such exclusion is explicitly stated.Furthermore, references to “one embodiment” of the present invention arenot intended to be interpreted as excluding the existence of additionalembodiments that also incorporate the recited features. Moreover, unlessexplicitly stated to the contrary, embodiments “comprising” or “having”an element or a plurality of elements having a particular property mayinclude additional such elements not having that property.

Turning to the figures, FIG. 1, depicted therein is an overview 10 ofthe invented system. The system comprises a series of warehouse shelves12, each shelf having a shelf front 22. Containers 18 of products arestored on each shelf. To access the containers 18, a moveable frame 20approaches the shelf fronts 22. The moveable frame 20 includes a liftingdevice 14, such as the robotic arm shown in FIG. 1. The moveable frame20 also includes a gripping device 16, capable of moving in anydirection within the moveable frame 20. The moveable frame 20 includes astorage ledge 26.

In use, the moveable frame 20 approaches a bank of shelves 12. The ledge26 moves into the required position to match the height of the shelffront 22. The lifting device 14 retrieves containers from the ledge 26and places them on the shelf 12. While the lifting device 14 is placingcontainers, the gripping device 16 is arranging containers on the ledge26 to allow the lifting device 14 to place containers 18. Once allcontainers are placed or retrieved form the shelf 12, the ledge 26lowers and the containers 18 are retrieved by the mobile robot 24. Themoveable frame 20 thereafter moves to a different bank of shelves.

As shown in FIG. 2, the lifting device 14 includes an end of arm tool(EOAT) which allows the lifting device 14 to interact with containers18. The end of arm tool in FIG. 2 comprises forks 36 and suction cups38. The details of the operation of the gripping device 16 are shown inFIG. 3, while details of the top of the shelf rack are shown in FIG. 4.FIG. 5 shows the exchange point 42 between the mobile robot 24 and themobile frame 20.

Turning to the shelf power transfer options, as shown in FIGS. 6A-D,containers 18 move along the shelf 12 using a mechanism. As shown inFIG. 6A, the mechanism comprises a shelf sprocket 50 which is driven bya lifting device 14 end of arm tool sprocket 52. The shelf 12 mechanismalso includes a pulley 54. By moving its sprocket 52, the lifting device14, which includes an end of arm tool 15, can move the containers 18 onthe shelf 12, even though the shelf does not include any autonomouspower. Products from the end of arm tool belt 56 are transferred to theshelf 12. The belt 56 is supported by the forks 36. As can be seen inFIG. 6A, the shelf 12 is substantially parallel to the floor of thewarehouse.

In the alternative design shown in FIG. 6C, the lifting device 14includes a moveable rod 70 which includes one or more fingers 74. Therod 70 is rotated in place and fingers 74 are moved in place such thatwhen the rod 70 is moved in the direction w product containers 18 movein the direction ω.

An alternative embodiment of the shelf 12 power transfer mechanism isshown in FIG. 6B. The mechanism comprises a lifting device end of armtool 15 which includes a powered rotating shank 62 having an irregularcross-section. The shank 62 is removably received by the shelf actuator64, such that rotational motion of the shank 62 is translated intolateral motion of the shelf 12 resulting in movement of the containers18. As shown in FIG. 6D, the lifting device 14 product placement toolincludes a rod controller 76 having selective appendage activator 78. Inone embodiment, the appendage activator 78 comprises gripper fingers.

Several alternative shelf 12 concepts are shown in FIGS. 7A-B. Theembodiments shown in FIGS. 7A-B are designed to work withgravity-assisted flow racks.

In the various depicted embodiments, a benefit of system which includesthe moveable frame 20, also referred to as the roboframe is that it canreliably process, place, and pick containers in a technicallychallenging environment. For example, the roboframe compensates foruneven floors, misaligned racks, and other environmental issues. Theroboframe and devices attached to it include onboard sensors to adjustthe operation of the devices. Therefore, the use of the roboframe doesnot require a retrofit of the warehouse, nor does it require extensiverepairs to a warehouse.

System Overview

Turning to FIG. 8 depicted therein is a top-down schematic overview of afacility which uses an embodiment of the system. The facility 100 isshown as using a larger aisle 102 and a series of smaller aisles 104.The larger aisle 102 facilitates movement in two directions by mobilerobots 110. As will be discussed in detail below, each mobile robot 110is equipped with a platform for transporting of bins, trays, carts,racks, and other product payload containers.

The larger aisle 102 acts a type of a mobile robot 110 thoroughfare withmarkings 103, both visible and invisible, designed to guide the mobilerobots 110 and to assist the mobile robot 110 sensors in determiningeach robot's location within the premises 100.

The narrower aisles 104 separate shelving units or racks 106. FIG. 8depicts the shelving units 106 predominantly as empty, but that is onlyfor purposes of clarity of the figure. One region 108 of the shelvingspaces is shown as filled with containers 112 of various sizes.

The narrower aisles 104 are used by roboframes 120, which will bedescribed in detail herein. Each roboframe 120 moves in an aisle 104 toreach a particular storage location within a rack 106. Each roboframeincludes an area 122 where a mobile robot 110 can deposit its payload.The roboframe, using components described below, interacts withindividual racks 106 to facilitate movement of product from each rack106 to a roboframe 120 which is then received by a mobile robot 110 forfurther delivery or processing. Analogously, the roboframe 120 allowsfor movement of product from a mobile robot 110 to a roboframe 120 andthen to a specific location on a rack 106.

While in FIG. 8, each narrow aisle 104 is shown as occupied by aroboframe 120, in one embodiment, a single roboframe 120 interacts withmultiple aisles 104.

The facility 100 also includes a guard 109 to prevent unauthorized entryto the area occupied by roboframes 120 and mobile robots 110. This guard109 ensures that the autonomous systems can operate presuming thatunauthorized persons will not enter the area. This increases thethroughput of the system and allows the various components to eliminatesensors which would otherwise be needed to detect personnel and stop theautonomous components to prevent collisions. The guard 109 includesopenings to allow mobile robots to pass through the perimeter, and oneor more portals 111 to allow the roboframes 120 to enter the aisles 104.

As shown in FIG. 8, the mobile robots 110 transport product containersbetween roboframes 120 and with external product storage points. Theproducts are stored in totes, as well as bins, and trays. Each containersystem employs computer-readable identifiers to allow for real-timetracking of product locations. In one embodiment, the mobile robots 110include a scale which allows for cross-checking of whether or not theexpected product weight has been met.

As will be described fully below, the shelving or racks 106 used by thesystem are low cost, have few components (none of which are powered) andcan be adjusted to various heights. The racks 106 can be expanded asneeded and reconfigured to carry product containers 112 of variousshapes and sizes.

Roboframe and Rack Details

Turning to FIG. 9, shown therein are the details of the roboframe 120and rack 106 and containers 112, shown in FIG. 8. While a single rack106 is shown in FIG. 9, as can be appreciated form the schematicoverview of FIG. 8, the system is designed to operate with many racksconnected together, and with the roboframe 120 surrounded on both sidesby arrays of racks 106. Also visible in FIG. 9 is the mobile robot 110,as it travels to the roboframe 120.

Turning first to the roboframe 120, the roboframe 120 is built fromseveral vertical members 124 and a pair of top horizontally extendingmembers 126. The vertical members 124 are attached to a mobile base 128,which includes wheels 130 and sensors 132 at each corner of the base128, in one embodiment. The sensors include lidar, RF-tag readers, andthe like. The sensors 132 also include a warning light, a buzzer, orother indicator, to warn of expected movement of the roboframe 120.While the sensors are placed on corners of the roboframe 120, as shownin FIG. 9, the roboframe base 128 is not exactly rectangular, with mostcorners having a rounded feature to facilitate turning of the roboframe120. In one embodiment, additional sensors are located in othercomponents of the roboframe 120, such as encoders in the wheels, whichassist the roboframe in determining its relative location.

The wheels 130 comprise an irregular shape with compressible features toprevent slippage of the roboframe 120 while it is loaded with product.The wheels 130 are designed for travel along a relatively flat surface,as may be found in a distribution center. In one embodiment, a mecanumall wheel drive mechanism is used, which allows the wheels to move inany direction. The wheels are highly precise and the location of theroboframe 120 is determined using steering accuracy, with no floor-basedguidance systems required, in one embodiment. The wheels providesufficient padding to prevent transferring force to the guide rail 138.

In one embodiment, the roboframe 120 is thethered to a power source,such as a buss bar or umbilical. Communications between the roboframe120 and a central operations system is accomplished using wirelesscommunications.

The top horizontal members 126 of the roboframe also include guidestabilizers 136, which engage with guiderails 138 found near or on thetop of the rack 106. The guide stabilizers 136 use a quick connectsystem to engage with the guide rails 138. In one embodiment, the guiderails 138 further comprise a pair of conductors so as to provide powerto the roboframe 120 components. The guide stabilizers 136 includecorresponding conductors to make contact with the guide rail 138energized conductors. The guide rail 138 in another embodiment includesan induction coil to transfer energy to the guide stabilizers 136without direct physical connection between the two components.

In operation, the roboframe 120 travels to a rack 106 location, theclamp guide stabilizers 136 engages with the guide rail 138, theroboframe 120 performs its functions as described below, and the clampguide stabilizers 136 release. The roboframe 120 then travels to thenext location. In one embodiment, the rail 138 is mounted directly to awall or other physical component. The design of the rail 138 is suchthat the roboframe 120 can be deployed even if there no racks forinteraction, such as at the end of an aisle or in a stand-by area. Thedesign is such that rails 138 may be daisy chaned in order to getcontinuous support and power transfer down the length of the facilityaisle.

The mobile base 128 includes an area 122 dedicated to interactions withthe mobile robot 110. In the embodiment shown in FIGS. 8 and 9 the area122 comprises rollers where mobile robots 110 can retrieve or depositpayloads 112. During the time a mobile robot 110 interacts with the area122, an engagement arm 142 holds the mobile robot 110 in place. Whendepositing payloads 112, the mobile robot 110 engages its conveyor tomove the payload from the mobile robot 110 to the area 122. The area 122includes multi-directional conveyors, such as rollers, balls, or thelike. The area 122 conveyor shifts the payload to the left and clearinga portion of the area 122 for a different payload which is to ready tobe picked up. When the mobile robot 110 is being provided the payload112, the area 122 conveyors move a payload stack to the mobile robot 110held in place by the engagement arm 142.

A platform 140 moves along any vertical position of the vertical members124.

Each corner of the platform 140 engages with a corresponding verticalmember 124. In one embodiment, the engagement mechanism comprises a railwith corresponding wheels to engage the rail. In another embodiment,each corner uses a pair of ratchet wheels which engage one another andare locked in place with a pawl. In yet another embodiment, a twistingtype mechanism is used.

While in one embodiment each corner includes a powered mechanism tosupport movement, in another embodiment, only a pair of opposing cornersof the platform 140 include active movement mechanisms. In thisembodiment, the remaining corners act to balance the platform 140.

In every embodiment, the platform 140 is maintained as substantiallyparallel to the top horizontal members 126.

The platform is divided into several logical areas. In one embodiment,the part of the platform closest to the mobile robot area 122 is thestack buffer 144. Items in the stack buffer 144 are manipulated by thegantry 146, which moves up and down within the moving platform 140,picking payloads up from one end of the platform and moving the payloadsto other parts of the platform, as well as stacking the payloads one ontop of another.

The gantry 146 includes a hook-based mechanism to engage with corners ofthe payload containers, in one embodiment. In another embodiment, thegantry 146 also includes an electromagnet.

The gantry 146 moves the payload containers to the part 148 of theplatform 140 which is furthest away from the mobile robot area 122. Thatpart 148 of the platform is where the robotic arm 150 interacts with thepayloads. The robotic arm 150 retrieves containers from its area 148,loads them to the robotic end of arm tool 152 and transfers them to orfrom the rack 106. The end of arm tool 152 is discussed in detail below.

The platform 140 moves with the robotic arm 150 and its primaryresponsibility is the creation of stacks to be loaded by the end of armtool on the robotic arm 150. Stacks of payloads are exchanged with themobile robot while the platform 140 is lowered to the mobile base 128and the mobile robot 110 is docked with the roboframe 120. In oneembodiment, the maximum weight per stack is 100 to 500 pounds.

The robotic arm 150 includes two joints capable of rotational motion anda wrist joint which controls the end of arm tool 152.

In one embodiment, the robotic arm 150 is mounted at a fixed base 154 onthe platform 140. In another embodiment, the robotic arm 150 base 154can move up and down the sides of the platform 140. In this embodiment,the joints on the robotic arm do not require the same degree of freedomof movement as on the embodiment where the robotic arm 150 is fixed inplace.

A robotic arm 150 mounted on the platform 140 includes sensors, such ascameras mounted on its wrist and end of arm tool. The robotic arm 150uses the sensors to determine when to transfer payloads from theplatform 140 area 148 to the end of arm tool 152. The robotic arm 150has sufficient freedom of movement in its joints to reach up to fourcolumns of product and process both sides of the narrow aisle 104 shownin FIG. 8.

In one embodiment, the maximum weight of a payload, such as a tray or abin is 50 pounds, which is dictated by the carrying capacity of theplatform 140, gantry 146, and robotic arm 150. As the robotic arm 150must accommodate not only a payload, but also its sophisticated end ofarm tool 152, its carrying limit is the determining factor for totalsystem capacity in most embodiments.

Having access to both sides of an aisle, the robotic arm 150 can accessup to 640 trays in one configuration. In operation, the payloads therobotic arm 150 requires are arranged by the gantry 146 in the roboticarm area 148. 90% of payload containers that are needed are found in therobotic arm area 148. The few containers that are not in an expectedlocation are moved to the area 148 by the gantry 146.

In many circumstances, when the robotic arm 150 is retrieving containersfrom the rack 106, the items are found in the front of the rack 106.However, the robotic arm will use a set down process and place item inits area 148 from the rack 106 when the robotic arm must retrieve anitem from the back of the shelf on a rack 106. In this set down process,the gantry moves items from the arm area 148 to the buffer area 144,freeing up space for the robotic arm to transfer payloads from the rack106.

In one embodiment, the cycle times for the system are as follows. 15seconds to pick a tray from the stack found in the robotic arm area 148,transfer the tray to the robotic arm 150 end of arm tool 152, andtransfer the item to the rack 106. Similarly, the robotic arm 150requires 15 seconds to pick a tray from the rack 106 transfer to the endof arm tool 152, and move to the stack of items in the area 148.

End of Arm Tool

The interaction of the end of arm tool 152 and the rack 106 is shown inFIG. 10. The end of arm tool 152 is mounted to the wrist of the robot150. The end of arm tool comprises a cage like structure 155 with top156 and bottom 158 substrates. While the top 156 and bottom 158substrates are substantially identical in one embodiment, in anotherembodiment, the substrates 156, 158 have different configurations. Eachsubstrate also includes weight saving openings 160. However, thesubstrates 156, 158 contain sufficiently rigid materials to preventdeformation of the cage 155.

Similarly to the substrates 156, 158, the cage 155 sides 162 comprise aslittle material as possible, while ensuring structural stability for thecage 155. As is shown in detail in the remaining figures, the cage 155encloses two conveyors 164, 166 which are independently operated, in oneembodiment. The conveyors 164, 166 transfer payloads from the end of armtool 152 back to the platform 140 described above, or to the rack 106.

The conveyors 164, 166 are powered by a mechanism 168, such as a motorconnected to a differential which in turn transfers motion to the wheelsof each conveyor 164, 166.

Overall, the end of arm tool has a simple design with a minimal numberof powered active components. In one embodiment, only the mechanism 168for the conveyors 164, 166 is a powered component, the remainingelements being passive.

The end of arm tool with wide conveyors and other features describedbelow, provides a large tolerance for misalignment. Therefore, therobotic arm 150 does not need to move the end of arm tool 152 withextreme precision.

The details of the interaction of the end of arm tool 152 and a rack 106are shown in FIG. 11. The end of arm tool 152 includes hooks 170 whichengage with apertures 172 on each shelf comprising the rack 106. Duringalignment of the end of arm tool 152 with the rack 106, the hooks 170engage the sides of the apertures, which include profiles to guide thehooks 170 into proper alignment with the apertures 172.

In one embodiment, a low voltage continuity sensor determines once thehooks 170 have made contact with the rack 106 apertures 172. In anotherembodiment, the end of arm tool 152 sensors, such as a camera, determinewhen the end of arm tool 152 has been aligned with the rack 106.

The end of arm tool 152 includes an array of six drive wheels 174, whichengage with a drive area 176 on an axle 178 of a shelf conveyor 180. Thewheels 174 transfer motion to the shelf moving the shelf conveyor 180 ineither direction. The motion of the wheels 174 is created by a frictiondrive motor 182 mounted on the end of arm tool 152.

Inasmuch as the power transfer mechanism uses an array of six wheels174, and the six wheels 174 engage a wide friction area 176, the twocomponents of the system do not need to be exactly aligned. Further, aspace between the conveyor on the end of arm tool 152 and the shelfconveyor 180 is permissible, so long as the space is not large enough toallow a payload to become stuck between the two conveyors.

Another view of the six wheel 174 assembly is depicted in FIG. 12. Asshown in that embodiment, the six wheel assembly 174 includes a topmotor 182 and a bottom motor 184. In other embodiments, not all wheels apowered by a motor, with only a single source of movement used.

As can be appreciated from FIGS. 11 and 12, the rack 106 includes nopowered components. Instead, the shelf conveyor 180 is entirely passivewith all motion of that shelf being the responsibility of the end of armtool 152.

As shown in FIG. 12, one corner of the end of arm tool 152 includes acamera 186. In other embodiments, not shown, additional sensors aremounted to the end of arm tool. The camera 186 is used to align the endof arm tool with the rack 106.

While the discussion above involved the interaction between the end ofarm tool 152 and the rack 106, analogous structures are found on theplatform 140 and so the end of arm tool 152 engages with the platform140 in a similar fashion.

In one embodiment, the end of arm tool includes identical hooks 170 andwheel 174 assemblies on each side of the end of arm tool so as to allowinteraction of the end of arm tool with either side of the rack 106 ormoving platform 140.

In use, the end of arm tool can independently interact with up to twosets of containers at a time, as the end of arm tool has two independentconveyors 164, 166 (shown in FIG. 10). An end of arm tool loaded withone payload, can travel to a shelf, pick up another container from ashelf, rotate the arm tool by 180 degrees, and then put the secondcontainer on the same shelf. In this way, the end of arm tool canreplace containers with only one full motion of the robotic arm.

Similarly, the robotic arm can swap containers and reverse their orderon the shelf. In this process, the robotic arm starts with an empty endof arm tool, loads a first container, rotates by 180 degrees the tool tothe empty side, loads a second container, rotates the tool again, thenreturns the first container to the shelf, followed by the secondcontainer. In this process the robotic arm can reverse the order ofitems on the rack without using any intermediate storage, such as theplatform 140.

Further, the robotic arm can swap containers across aisles by picking apayload from one side and a second side of the aisle, then changing thecontainer's positions.

The benefits of the end of arm tool arrangement include a decrease inthe stacking and de-stacking of product containers on buffer areas ofthe platform and a decrease in the operations required by the gantrytool.

Rack Overview

An overview of the rack 106 pursuant to one embodiment of the inventionis shown in FIG. 13. The rack 106 is designed with shelves for totes 190and trays 192. Each rack 106 shelf has a front 194 which is the onlypoint at which the roboframe interacts with the rack 106. The frameincludes marks 196 to assist in alignment of the end of arm tool, whichis equipped with a camera.

Shelves which comprise the rack 106 are individually serviceable andreplaceable. The shelves conveyors 180 do not have powered components,with all the motion being originated with the end of arm tool. Theshelves are adjustable for different container heights, with the largestcontainers being reserved for the top-most shelf.

Each shelf conveyor 180 includes a frictional engagement surface on theside facing the payloads to ensure that the payloads do not shift duringstorage. The reverse side of the conveyor 180 includes a low frictionstrip. This allows the conveyor 180 to move up to several hundred poundsof payloads that are located on the shelf.

Robotic Arm Operation

The details of the operation of the robotic arm 150 are shown in FIG.14. As described above, the robotic arm 150 is mounted on a platform154, attached to the roboframe 120.

As shown in the embodiment of FIG. 14, the robotic arm 150 comprises astationary base 154 with a rotating base plate 200 installed thereon.The base plate 200 allows the robotic arm 150 to extend from one aisleto the other aisle without fully extending all the joints of the roboticarm. In a fully-extended configuration, the maximum weight which can besupported by the joints decreases. During movement of the roboframe, therobotic arm 150 is placed in an extended position substantially parallelwith the roboframe. In this configuration, pressure on the arm joints isminimized. Further, the end of arm tool is aligned so as to not extendbeyond the sides of the roboframe 120.

Attached to the rotating base plate 200 is the arm base 202 withcounterweights 206. On the opposing end of the arm base 202 is arevolute joint 204, which controls the movement of the first link 208.The revolute joint 204 allows the arm to move closer or away from theroboframe 120.

The first link 208 has a substantially rectangular profile, in oneembodiment. In another embodiment, the first link 208 has an I-beamprofile.

The opposing end of the first link 208 is a second revolute joint 210.The second revolute joint 210 connects the first link 208 to the secondlink 212.

The second link 212 is substantially cylindrical, in the depictedembodiment. The second link 212 includes a number of sensors. While theshapes of the first link and second link are depicted as rectangular andcylindrical respectively, a number of shapes for the links is envisionedin other embodiments, not shown.

The end of the second link 212 which is opposite of the second revolutejoint 210 ends in a wrist joint 214. The wrist joint 214 allows forrotation of the end of arm mounting plate 216 in any direction. The endof arm tool 152 (shown only partially in FIG. 14) is attached to the endof arm mounting plate 216.

This arrangement allows the robotic arm 150 to move in any number ofdirections, and reach either aisle 104, as shown in FIG. 8.

Although exemplary implementations of the invention have been depictedand described in detail herein, it will be apparent to those skilled inthe relevant art that various modifications, additions, substitutions,and the like can be made without departing from the spirit of theinvention and these are therefore considered to be within the scope ofthe invention as defined in the following claims.

It is to be understood that the above description is intended to beillustrative, and not restrictive. For example, the above-describedembodiments (and/or aspects thereof) may be used in combination witheach other. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the inventionwithout departing from its scope. While the dimensions and types ofmaterials described herein are intended to define the parameters of theinvention, they are by no means limiting, but are instead exemplaryembodiments. Many other embodiments will be apparent to those of skillin the art upon reviewing the above description. The scope of theinvention should, therefore, be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. In the appended claims, the terms “including” and“in which” are used as the plain-English equivalents of the terms“comprising” and “wherein.” Moreover, in the following claims, the terms“first,” “second,” and “third,” are used merely as labels, and are notintended to impose numerical requirements on their objects. Further, thelimitations of the following claims are not written inmeans-plus-function format and are not intended to be interpreted basedon 35 U.S.C. § 112, sixth paragraph, unless and until such claimlimitations expressly use the phrase “means for” followed by a statementof function void of further structure.

The embodiment of the invention in which an exclusive property orprivilege is claimed is defined as follows:
 1. A method for movement ofproducts, the method comprising: a) providing a facility wherein saidfacility contains warehouse shelves, each shelf having a front andwherein containers of products are stored on each shelf; b) providing atleast one moveable frame which travels to each shelf front to access thecontainers stored on said shelf wherein said moveable frame includes arepositionable storage ledge; c) providing a lifting device attached tosaid moveable frame; d) providing a gripping device attached to saidmoveable frame; e) providing at least one mobile robot; f) moving saidmoveable frame to a location of a specific shelf; and g) positioningsaid storage ledge in vertical position required to access said specificshelf; wherein said lifting device and gripping device access containerson the storage ledge of said moveable frame and said specific shelfthereby transferring product containers from the specific shelf to saidstorage ledge and transferring product containers from the storage ledgeto said specific shelf.
 2. The method of claim 1 further comprising: h)moving said moveable frame to a new shelf; and i) repeating step f. 3.The method of claim 1 wherein said facility includes a guard to preventunauthorized access to areas occupied by mobile robots and moveableframes.
 4. The method of claim 1 wherein said facility includes two ormore moveable frames and said at least one mobile robot transfersproducts between said two or more moveable frames.
 5. The method ofclaim 1 wherein said storage ledge is organized into multiple logicalareas.
 6. The method of claim 5 wherein said gripping device comprises agantry which moves product containers between said multiple logicalareas of said storage ledge.
 7. The method of claim 5 wherein saidgantry moves products to a mobile robot.
 8. The method of claim 1wherein said lifting device comprises a robotic arm.
 9. The method ofclaim 8 wherein said robotic arm comprises an end of arm tool whereinsaid end of arm tool allows the robotic arm to interact with productcontainers.
 10. The method of claim 8 wherein said end of arm toolfurther includes a power transfer mechanism.
 11. The method of claim 10wherein said facility warehouse shelves do not include poweredcomponents and are not active unless said end of arm tool power transfermechanism engages with at least one shelf.
 12. The method of claim 1wherein said at least one moveable frame comprises vertical members, apair of horizontally extending members attached at a top of end of saidvertical members wherein opposing bottom end of vertical members areattached to a mobile base; wherein said moveable frame further includesa connection to a power source.
 13. The method of claim 12 wherein saidmobile base comprises wheels and sensors at each corner of said mobilebase and wherein said mobile base is shaped as a rectangle with roundedcorners.
 14. The method of claim 13 wherein sensors comprise lidar andRF-tag reader.
 15. The method of claim 13 wherein said mobile basefurther includes an indicator of movement.
 16. The method of claim 1further comprising: h) lowering said storage ledge and docking saidmobile robot to the lowered storage ledge; and i) transferring contentsof said storage ledge to said mobile robot.
 17. The method of claim 16further comprising: j) moving said moveable frame to a new shelf; and k)repeating steps f to i.
 18. The method of claim 16 wherein docking ofsaid mobile robot to said moveable frame comprises engaging said mobilerobot depositing payload on a frame surface by transferring same using aconveyor from the moveable frame to said mobile robot.
 19. The method ofclaim 16 wherein said facility includes at least one larger aisle and atleast one smaller aisle.
 20. The method of claim 19 wherein said mobilerobot traverses said larger aisle and wherein said moveable frametraverses said smaller aisle.